US10431440B2 - Methods and apparatus for processing a substrate - Google Patents

Methods and apparatus for processing a substrate Download PDF

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Publication number
US10431440B2
US10431440B2 US14/975,793 US201514975793A US10431440B2 US 10431440 B2 US10431440 B2 US 10431440B2 US 201514975793 A US201514975793 A US 201514975793A US 10431440 B2 US10431440 B2 US 10431440B2
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targets
shield
process chamber
chamber
chamber body
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US14/975,793
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US20170178877A1 (en
Inventor
Rongjun Wang
Anantha K. Subramani
Chi Hong Ching
Xianmin Tang
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Applied Materials Inc
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Applied Materials Inc
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Assigned to APPLIED MATERIALS, INC. reassignment APPLIED MATERIALS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHING, CHI HONG, SUBRAMANI, ANANTHA K., TANG, XIANMIN, WANG, RONGJUN
Priority to PCT/US2016/066080 priority patent/WO2017112439A1/en
Priority to SG11201804855SA priority patent/SG11201804855SA/en
Priority to EP16879880.9A priority patent/EP3391406A4/en
Priority to JP2018550653A priority patent/JP7066626B2/ja
Priority to KR1020187020862A priority patent/KR102663848B1/ko
Priority to CN201680074710.6A priority patent/CN108604533B/zh
Priority to TW105141667A priority patent/TWI778947B/zh
Publication of US20170178877A1 publication Critical patent/US20170178877A1/en
Publication of US10431440B2 publication Critical patent/US10431440B2/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J37/00Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
    • H01J37/32Gas-filled discharge tubes
    • H01J37/34Gas-filled discharge tubes operating with cathodic sputtering
    • H01J37/3411Constructional aspects of the reactor
    • H01J37/3441Dark space shields
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/08Oxides
    • C23C14/082Oxides of alkaline earth metals
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34Sputtering
    • C23C14/3407Cathode assembly for sputtering apparatus, e.g. Target
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34Sputtering
    • C23C14/3464Sputtering using more than one target
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J37/00Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
    • H01J37/32Gas-filled discharge tubes
    • H01J37/32431Constructional details of the reactor
    • H01J37/32458Vessel
    • H01J37/32477Vessel characterised by the means for protecting vessels or internal parts, e.g. coatings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J37/00Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
    • H01J37/32Gas-filled discharge tubes
    • H01J37/34Gas-filled discharge tubes operating with cathodic sputtering
    • H01J37/3411Constructional aspects of the reactor
    • H01J37/3414Targets
    • H01J37/3426Material
    • H01J37/3429Plural materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J37/00Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
    • H01J37/32Gas-filled discharge tubes
    • H01J37/34Gas-filled discharge tubes operating with cathodic sputtering
    • H01J37/3411Constructional aspects of the reactor
    • H01J37/3447Collimators, shutters, apertures
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/02104Forming layers
    • H01L21/02107Forming insulating materials on a substrate
    • H01L21/02109Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates
    • H01L21/02112Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer
    • H01L21/02172Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing at least one metal element, e.g. metal oxides, metal nitrides, metal oxynitrides or metal carbides
    • H01L21/02175Forming insulating materials on a substrate characterised by the type of layer, e.g. type of material, porous/non-porous, pre-cursors, mixtures or laminates characterised by the material of the layer the material containing at least one metal element, e.g. metal oxides, metal nitrides, metal oxynitrides or metal carbides characterised by the metal
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/02104Forming layers
    • H01L21/02107Forming insulating materials on a substrate
    • H01L21/02225Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer
    • H01L21/0226Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process
    • H01L21/02263Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase
    • H01L21/02266Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by physical ablation of a target, e.g. sputtering, reactive sputtering, physical vapour deposition or pulsed laser deposition

Definitions

  • Embodiments of the present disclosure generally relate to methods and apparatus for processing a substrate.
  • PVD Physical vapor deposition
  • Dielectric PVD sputtering has many applications in the semiconductor industry, such as, for example, hafnium oxide, tantalum oxide, aluminum oxide for Resistive random-access memory (ReRAM) and conductive-bridging random-access memory (CBRAM) filaments, magnesium oxide for STT-RAM barrier layers, tantalum oxide and titanium oxide for antireflection layers for image sensors, etc.
  • Dielectric materials may be deposited using reactive sputtering, where a metallic conductive target is used and reacts with an oxygen or nitrogen plasma to deposit dielectric, or using a composite non-conductive target with RF power (either capacitive or inductive coupling) to directly sputter the target materials onto the substrate.
  • the second method is typically used for applications in which substrate oxidation or nitridation during the dielectric deposition is not desirable, barring the use of reactive gases in such applications.
  • an angled multicathode chamber is used.
  • a dielectric target is connected to an RF power supply, and a metallic target is connected to a DC power supply.
  • a rotating shield is used to avoid cross-contamination between the targets during sputtering.
  • the purpose of the metallic target is to paste the shield to recover the deposition rate due to grounding loss caused by dielectric coating. The metallic paste also helps prevent the peeling and flaking of dielectric particles on the shield.
  • a process chamber includes: a chamber body defining an interior volume; a substrate support to support a substrate within the interior volume; a plurality of cathodes coupled to the chamber body and having a corresponding plurality of targets to be sputtered onto the substrate; and a shield rotatably coupled to an upper portion of the chamber body and having at least one hole to expose at least one of the plurality of targets to be sputtered and at least one pocket disposed in a backside of the shield to accommodate and cover at least another one of the plurality of targets not to be sputtered, wherein the shield is configured to rotate about and linearly move along a central axis of the process chamber.
  • a method for processing a substrate disposed on a substrate support in a process chamber includes: rotating a shield disposed within the process chamber to expose a dielectric target through a hole in the shield; moving the shield up along a central axis of the process chamber away from the substrate support to a retracted position; depositing dielectric material from the dielectric target onto the substrate; removing the substrate from the process chamber; moving the shield down along the central axis towards the substrate support; rotating the shield to expose a metallic target through the hole in the shield; pasting metallic material from the metallic target onto interior surfaces of the process chamber; and flowing oxygen into the process chamber to oxidize the pasted metallic material.
  • FIG. 3 depicts a schematic view of an upper portion of a multi-cathode processing chamber in accordance with some embodiments of the present disclosure.
  • FIG. 5 depicts a bottom view of a shield disposed in the multi-cathode processing chamber of FIG. 3 in accordance with some embodiments of the present disclosure.
  • FIG. 6 is a flowchart illustrating a method of processing a substrate in accordance with some embodiments of the present disclosure.
  • Embodiments of methods and apparatus for processing a substrate are provided herein.
  • the disclosed methods and apparatus may advantageously improve target life, prolong the time period needed before cleaning, and alleviate deposition rate drifting while substantially minimizing or eliminating cross-contamination between targets.
  • a multi cathode-PVD chamber (i.e. process chamber 100 ) includes a plurality of cathodes 102 having a corresponding plurality of targets (at least one dielectric target 104 and at least one metallic target 106 ), (for example, 5 cathodes) attached to the chamber body (for example, via a chamber body adapter 108 ).
  • the metallic target(s) may be formed of metals such as, for example, tantalum, aluminum, titanium, molybdenum, tungsten, and/or magnesium or of a conductive metal oxide such as, for example, titanium oxide, titanium magnesium oxide, and/or tantalum magnesium oxide.
  • other metals and/or conductive metal oxides may alternatively be used.
  • the processing chamber includes a substrate support 132 having a support surface 134 to support a substrate 136 .
  • the process chamber 100 includes an opening 150 (e.g., a slit valve) through which an end effector (not shown) may extend to place the substrate 136 onto lift pins (not shown) for lowering the substrate onto the support surface 134 .
  • an opening 150 e.g., a slit valve
  • An actuator 124 is coupled to the shaft 122 opposite the shield 116 .
  • the actuator 124 is configured to rotate the shield 116 , as indicated by arrow 126 , and move the shield 116 up and down along the central axis 130 of the process chamber 100 , as indicated by arrow 128 .
  • the inventors have observed that when the shield 116 is moved up into a retracted position so that a face of the shield surrounding the hole 118 is behind a face of the target (e.g., dielectric target 104 ) facing the substrate 136 , materials sputtered in a dark space surrounding the target (e.g., on a sidewall of the hole 118 ) are advantageously minimized. As a result, materials sputtered from one target (e.g.
  • the shield 116 may be provided with a pocket 120 to house a target not being sputtered.
  • the pocket advantageously prevents scattering of the sputtered target from being deposited on the target not being sputtered. Although such scattering is inevitable, the pocket 120 ensures that the scattering does not contaminate the sputtered surface of the non-sputtered target. As a result, contamination of the target not being sputtered is further reduced.
  • the process chamber 100 includes a plurality of grounding rings 144 to provide improved grounding of the shield 116 to the grounded chamber body adapter 108 when the shield is in the retracted position.
  • the RF grounding rings 144 advantageously prevent the shield 116 from getting negatively charged by minimizing the energy between the plasma and the shield. As a result, the chances of the shield being sputtered are further reduced.
  • the process chamber 100 further includes a process gas supply 146 to supply a predetermined process gas to an interior volume 105 of the process chamber 100 .
  • the process chamber 100 may also include an exhaust pump 148 fluidly coupled to the interior volume 105 to exhaust the process gas from the process chamber 100 .
  • the process gas supply 146 may supply oxygen to the interior volume 105 after the metallic target 106 has been sputtered.
  • the inventors have observed that flowing oxygen into the process chamber 100 after the metallic paste advantageously reduces the sputter yield of the pasted metallic material because the sputter yield of a metallic oxide (e.g., tantalum oxide) is significantly less than that of the metal (e.g., tantalum). As a result, contamination of the substrate 136 is further reduced.
  • a metallic oxide e.g., tantalum oxide
  • FIG. 2 depicts a bottom view of the shield 116 of FIG. 1 .
  • the plurality targets 104 , 106 are illustrated as five targets, more or fewer targets may be utilized for example, as shown in FIG. 4 and described below.
  • the shield 116 may include one hole 118 and four pockets 120 .
  • the shield 116 may alternatively include more than one hole 118 to expose more than one target to be sputtered.
  • FIG. 3 depicts a close-up of an upper portion of a process chamber in accordance with some embodiments of the present disclosure.
  • the elements of the process chamber in FIG. 3 that are the same or similar to corresponding elements of the process chamber 100 of FIG. 1 will be referred to with the same reference characters. As such, a description of these elements will be omitted here.
  • a shield 316 having a flat orientation may alternatively be used instead of the angled shield 116 in the process chamber 100 shown in FIG. 1 .
  • the targets 104 , 106 are parallel to the support surface 134 .
  • the shield 316 includes one or more holes 318 to expose one or more targets 104 , 106 to be sputtered.
  • the shield 316 also includes one or more pockets 320 to house one or more targets that are not being sputtered.
  • the hole 318 differs from the hole 118 of the angled shield 116 in that the hole 318 has a width 302 that is smaller than that of the hole 118 . Because the targets 104 , 106 are angled with respect to the support surface 134 , the hole 118 is large enough to allow the target being sputtered to pass through the hole 118 when the shield 116 is moved to a retracted position.
  • the width 302 of the hole 318 is only slightly larger than a width of the target. Because the gap between the target being sputtered (e.g., dielectric target 104 ) and the shield is smaller than that of the angled shield and targets shown in FIG. 1 , contamination is further reduced because less material is deposited on the sidewalls of the holes 318 .
  • the target being sputtered e.g., dielectric target 104
  • the inventors have discovered the flat orientation of the shield 316 and the targets 104 , 106 shown in FIG. 3 advantageously further improves the RA uniformity from less than 5% using the angled shield 116 of FIG. 1 to about 2-3% with the flat shield 316 .
  • the shield 316 is flat, more cathodes 102 may be used than with the angled shield 116 , assuming the same overall shield diameter.
  • the plurality of targets may include six targets: three dielectric targets 104 and three metallic targets 106 .
  • the shield 316 includes three non-adjacent holes 318 and three non-adjacent pockets 320 . Because the three non-adjacent holes 318 expose three targets to be co-sputtered, the throughput of the process chamber is increased three times over a single sputtered target because the deposition rate is three times that of the single sputter target. In addition, the overall target life is increased since the amount of material sputtered from each target is 2 ⁇ 3 less than a single sputtered target.
  • FIG. 4 Another advantage of the embodiment shown in FIG. 4 is that there is less deposition on the dark space of the shield surrounding each target (i.e., 2 ⁇ 3 less than that of a single sputtered target). As a result, contamination is further reduced and 2 ⁇ 3 less paste material is needed.
  • FIG. 5 depicts a configuration of a shield 516 in accordance with some embodiments of the present disclosure.
  • the shield 516 is substantially similar to the shield 316 depicted in FIGS. 3 and 4 except that the shield 516 includes two adjacent holes 518 and four pockets 520 .
  • the plurality of targets includes two adjacent dielectric targets 104 , two adjacent first metallic targets 106 formed of a first metal, and two adjacent second metallic targets 507 formed of a second metal.
  • the two adjacent second metallic targets 507 may be a formed of a second dielectric material different than that of the dielectric targets 104 .
  • the shield 516 may advantageously facilitate a stacked deposition process.
  • the two adjacent dielectric targets 104 may be formed of magnesium oxide
  • the two adjacent first metallic targets 106 may be formed of tantalum
  • the two adjacent second metallic targets 507 may be formed of magnesium.
  • direct sputtering of magnesium oxide from the two adjacent dielectric targets 104 or sputtering of magnesium from the two adjacent second metallic targets 507 and subsequent oxidization may alternatively be performed in the same chamber.
  • the sputtering of the two adjacent second metallic targets 507 and subsequent oxidization may be advantageous over direct sputtering of the dielectric targets 104 because the metal pasting needed after sputtering of the two adjacent second metallic targets 507 is less than that needed for the direct sputtering of the dielectric targets 104 .
  • FIG. 6 is a flowchart illustrating a method 600 of processing a substrate 136 in accordance with some embodiments of the present disclosure.
  • the shield 116 , 316 is rotated to expose the dielectric target 104 .
  • the shield is moved up along the central axis 130 of the process chamber 100 to a retracted position so that a face of the shield 116 , 316 surrounding the dielectric target 104 is behind a face of the target.
  • the dielectric material is deposited on the substrate 136 .
  • the substrate 136 is removed from the process chamber 100 .
  • the shield 116 , 316 is moved down along the central axis 130 of the process chamber 100 to an original position.
  • the shield is rotated to expose the metallic target 106 .
  • the shield 116 , 316 is moved up along the central axis 130 of the process chamber 100 to a retracted position so that a face of the shield 116 , 316 surrounding the metallic target 106 is behind a face of the target.
  • the metallic target 106 is sputtered to paste the shield 116 , 316 and the chamber 100 with the metallic material.
  • oxygen is flowed from the process gas supply 146 into the interior volume 105 to oxidize the pasted metallic material.

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US14/975,793 2015-12-20 2015-12-20 Methods and apparatus for processing a substrate Active 2036-06-15 US10431440B2 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US14/975,793 US10431440B2 (en) 2015-12-20 2015-12-20 Methods and apparatus for processing a substrate
JP2018550653A JP7066626B2 (ja) 2015-12-20 2016-12-12 基板を処理するための方法および装置
SG11201804855SA SG11201804855SA (en) 2015-12-20 2016-12-12 Methods and apparatus for processing a substrate
EP16879880.9A EP3391406A4 (en) 2015-12-20 2016-12-12 METHOD AND DEVICE FOR PROCESSING A SUBSTRATE
PCT/US2016/066080 WO2017112439A1 (en) 2015-12-20 2016-12-12 Methods and apparatus for processing a substrate
KR1020187020862A KR102663848B1 (ko) 2015-12-20 2016-12-12 기판을 프로세싱하기 위한 방법들 및 장치
CN201680074710.6A CN108604533B (zh) 2015-12-20 2016-12-12 用于处理基板的方法和设备
TW105141667A TWI778947B (zh) 2015-12-20 2016-12-16 用於處理基板的方法與設備

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US14/975,793 US10431440B2 (en) 2015-12-20 2015-12-20 Methods and apparatus for processing a substrate

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US20170178877A1 US20170178877A1 (en) 2017-06-22
US10431440B2 true US10431440B2 (en) 2019-10-01

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US (1) US10431440B2 (ko)
EP (1) EP3391406A4 (ko)
JP (1) JP7066626B2 (ko)
KR (1) KR102663848B1 (ko)
CN (1) CN108604533B (ko)
SG (1) SG11201804855SA (ko)
TW (1) TWI778947B (ko)
WO (1) WO2017112439A1 (ko)

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